VersaMax Profibus Network Interface Unit

June 2002 GFK-1552D

The Profibus Network Interface Unit is a Profibus slave module that acts
as controller for a set of I/O modules. Power for module operation is
provided by a power supply that installs directly on the NIU
Profibus NIU
power supply
Upgrading Previous Firmware Versions ___________
This firmware release replaces all previous versions. The new firmware
is backward-compatible with all previous module versions of the
Profibus NIU. All previous versions of the PBI001 module must be
upgraded to ensure correct operation of discrete outputs. An upgrade is
available at GEFanuc.com. and can also be ordered on disk (order
number 44A748011-G04) All firmware upgrades require cable
IC200CBL002, which connects the module to the personal computer
used to perform the upgrade.
This upgrade includes a new version of the GSD file (GEF_086A.GSD),
which replaces all previous GSD file versions.

Output Default/Hold Last State Operation __________________

The Default/Hold Last State Operation of outputs has changed from
previous releases.
Specifications __________________________________ Warning
Profibus network address 1 to 125
This may require application changes to account for the
Profibus network data rate 9.6Kbaud to 12Mbaud , auto-detected operational differences described below. Failure to account for
I/O data 375 bytes maximum. Up to 244 bytes of inputs or this new operation of the DEFAULT/HOLD LAST STATE function of
244 bytes of outputs. outputs could cause an unexpected equipment operation possibly
User diagnostic data 5 bytes maximum resulting in personal injury or property damage.
Indicators (5) Power LED indicates power The new operation is as follows:
OK LED indicates health of the NIU
Fault LED indicates presence of faults For an Output Module Configured to Default
Network LED indicates health of Profibus network Outputs go to their configured default state when communication is
Force LED(not used)
lost with the Profibus master. Outputs go to zero when the Profibus
Number of I/O modules 64 I/O modules per NIU (Up to 8 Racks with a master transitions from Operate to Clear mode. With a PLC
maximum of 8 I/O modules per rack.) Profibus master, the transition from Operate to Clear mode
Power Consumption +5V@250mA, +3.3V@10mA occurs when the PLC CPU transitions from Run to Stop mode.
Output Module Configured to Hold Last State
Product Description _____________________________ Outputs hold their last state when communication is lost with the
Profibus master. Outputs go to zero when the Profibus master
Revision: CF transitions from Operate to Clear mode. With a PLC Profibus
Firmware version: 2.20 master, the transition from Operate to Clear mode occurs when
the PLC CPU transitions from Run to Stop mode
GSD File version GEF_086A.GSD Version 1.10
Firmware upgrades: 44A748011-G04 Operating Notes/Restrictions for this NIU Version __
Profibus Certification: Certified as derivative of version 1.00.
Certificate available upon request The Profibus NIU is limited in the amount of configuration it can
accept for I/O modules on it station. The maximum number of
New Feature of this NIU Version ___________________ configuration identifiers allowed is 64. It is possible to exceed that
maximum when using expansion racks. It is important to calculate
This version of the Profibus NIU can be used with all VersaMax the number of configuration identifiers required to configure a
High-density Analog Modules. Profibus NIU system to determine if the system is within this limit.
This can be done by summing the configuration identifiers for each
Input Modules: IC200ALG261, IC200ALG262, IC200ALG263,
I/O module in the station as listed in the Profibus NIU Users
IC200ALG264
Manual. If the configuration size is exceeded, the Profibus NIU will
Output Modules: IC200ALG325, IC200ALG326, IC200ALG327, flash an error code 0x41.
IC200ALG328
When performing a firmware upgrade on an intelligent I/O module
Compatibility ___________________________________ in the NIU station, the controller should be put into stop mode, or
To be used in an expansion rack, analog modules the network cable should be removed from the NIU.
IC200ALG320, 321, 322, and 432 must be revision B or later. The main power supply for an NIU station and any booster power
Analog modules IC200ALG430 and 431 that are used in supplies that are used should be power cycled together. One
expansion racks must be revision C or later. power supply should be power cycled with the others.
This Profibus NIU is compatible with the AS-i Network Master
module.
Functional operation of discrete outputs has changed from
previous releases. When upgrading firmware in an existing
module, it may be necessary to alter the application program to
accommodate this difference. See the section "Output
Defaults" for more information.

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 VersaMax Profibus Network Interface Unit
June 2002 GFK-1552D

If the Profibus Watchdog timer expires on a Profibus NIU that is Quick Start Guide ______________________________
reporting extended diagnostic information to a Profibus master
(the PNIU is faulted), the extended diagnostic information is not 1. Install the NIU on the DIN Rail by simply clicking it into place.
reported to the master after the timeout. The PNIU remains in a
Note: The NIU and connecting carriers
faulted state but reports to the Profibus master that it has no
must be installed on the same section
extended diagnostic information (however, the correct fault
of 35mm x 7.5mm DIN rail.
information is reported via the NIUs Status/Control Bytes.).
This condition persists until either the PNIUs fault table is The DIN rail must have a conductive
cleared, or the current fault is read from the Status/Control (unpainted) finish for proper
Bytes. grounding.

Fixed for this Version ___________________________

During a firmware upgrade to an intelligent I/O module
(ALG240, 331, 620, 630, and MDD841), outputs now either
default or hold last state, according to their configuration.
During a firmware upgrade of the Profibus NIU, outputs now
either default or hold last state, according to their configuration.
The NIU can clear faults generated by a module in slot 8.
Profibus Global Control Clear Commands will consistently zero
outputs that are configured to Hold Last State or to default to a
non-zero value. (Profibus masters send this command when
they transition from Operate to Clear Mode this occurs in
PLC masters when the PLC CPU transitions from Run to
Stop Mode.)
If a configuration store or an intelligent I/O module firmware
update is performed on a Profibus NIU that is reporting
extended diagnostic information to a Profibus master, the NIU
will report the information after the configuration store or
firmware update completes. The fault information is also
reported via the NIUs Status/Control Bytes.
The Profibus NIU clears the Profibus output buffer after it
leaves the Data Exchange State. If a Read Output Data
telegram (SAP 57) is sent to the PNIU before it enters Data
Exchange again, the cleared output data is now returned.
Outputs configured to Default will transition to their configured
default value when the PNIU is processing a firmware upgrade
to an intelligent I/O module.
(Refer to the heading Module Installation for information about
space requirements or module orientation, or if you are installing
the NIU in an area of excessive vibration).
2. Install the Power Supply on the NIU.
The latch on the power supply must be
in the unlocked position.
Align the connectors and the latch post
and press the power supply module
down until the two tabs on the bottom of
the power supply click into place.
Turn the latch to the locked position to
secure the power supply to the top of
the NIU.
Complete the power supply wiring as described in the installation
instructions provided with the Power Supply.
3. Adjust the rotary switches on the front of the NIU using a
2.44mm (3/32in) flat screwdriver. These switches, marked Node
Address X100, X10 and X1 select the hundreds, tens and units
digits of the network address. Select any valid address in the
range 1-125. Always cycle power to the NIU after changing the
switch settings.
U 0 1 NODE
ADDRESS

Preinstallation Check ___________________________ X100

9 0 1
8 2
Carefully inspect all shipping containers for damage. If any 7 3 X10
6 5 4
equipment is damaged, notify the delivery service immediately. Save 9 0 1
the damaged shipping container for inspection by the delivery 8
7
2
3 X1
service. After unpacking the equipment, record all serial numbers. 6 5 4

Save the shipping containers and packing material in case it is

necessary to transport or ship any part of the system.
4. Connect the communications bus to the to the connector on
the front of the Network Interface Unit. (Refer to the heading Bus
Installation Guidelines for detailed bus installation
instructions.)
5. Remove the connector cover on the right-hand side of the
NIU. Do not discard this cover; you will need to install it on the
last carrier. It protects the connector pins from damage and ESD
during handling and use. Do not remove the connector cover on
the left-hand side.

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 VersaMax Profibus Network Interface Unit
June 2002 GFK-1552D

6. Install additional modules by mounting modules on their Panel-Mounting

carriers and sliding them along the DIN rail to fully engage
For best stability, the DIN rail should be installed on a panel using
the connectors in the sides of the carriers.
screws spaced approximately 5.24cm (6in) apart.
If excessive vibration is a factor the NIU should also be screwed down
to the mounting panel.
Note 1. Tolerances are +/- 0.13mm (0.005in) non-cumulative.
Note 2. 1.1-1.4Nm (10-12 in/lbs) of torque should be applied to M3.5 (#6-
32) steel screw threaded into material containing internal threads
and having a minimum thickness of 2.4mm (0.093in).
SEE NOTE 2.
4.3mm M3.5 (#6) SCREW
0.170in
SPLIT LOCK
7. Power up the NIU. The modules in the I/O station will WASHER

automatically be configured, starting at slot 1 in each rack FLAT WASHER

including expansion racks. If an empty slot or faulted module is 4.3mm

encountered, autoconfiguration for that rack stops. 0.170in 15.9mm
0.62in REF
Autoconfiguration then skips to the next rack and continues
5.1mm
until all racks are configured. 0.200in
TAPPED HOLE NIU
Note: If the I/O station includes any additional power supplies, IN PANEL

those power supplies should be turned on at the same time.

8. Observe the Module LEDs. The LEDs indicate the presence Removing the NIU from the DIN Rail
of power and show the operating mode and status of the NIU.
1. Turn off power to the power supply.
PWR Green indicates power is applied to the 2. (If the NIU is attached to the panel with a screw) remove the
PWR
NIU. power supply module. Remove the panel-mount screw.
OK OK Green indicates the NIU firmware is 3. Slide the NIU away from the other modules until the connector
FAULT operational. on the right side disengages from the next carrier.
NETWORK FAULT Amber indicates the NIU has detected a 4. With a small flathead screwdriver, pull the DIN rail latch out while
FORCE fault with itself or an I/O module. tilting the other end of the NIU down to disengage it from the DIN rail.
NETWORK Green indicates the NIU is successfully
transferring I/O on the network.
Bus Installation Guidelines ______________________
Amber indicates the NIU failed to be
parameterized or rejected the The proper cable for a Profibus network is a shielded twisted pair cable.
configuration sent by the master device. Profibus cable is sold simply as "Profibus Network Cable". The twisted
Off indicates the NIU senses no pair cable consists of a Green and a Red wire. Below are some of the
communication with the master device. characteristics of the Profibus network and cable.
FORCE (future) indicates the presence of any
forced I/O value. Always OFF. Network Topology Linear bus, terminated at both ends. Stubs possible.
Medium Shielded twisted pair cable. Shielding may be
omitted, depending on the environment.
vGeneral Module Installation Instructions ___________
Number of Stations 32 stations in every segment without repeaters.
Modules must be mounted on a With repeaters, extendible up to 127.
horizontal DIN rail. Transmission Speed 9.6, 19.2, 93.75, 187.5, 500, 1500 Kbits, 3 Mbits, 6
1 Mbits, 12 Mbits.
1. Allow sufficient finger clearance
for opening NIU door. Connector 9-pin D-sub connector
2. Allow adequate clearance for Cable Type Profibus DP
serial port cables. Impedance 135 to 165 Ohms (3 to 20 MHz)
133.35mm
(5.25in) 3. Allow adequate space for power Capacity < 30 pF per meter
wiring. Resistance < 110 Ohms per Kilometer
2 The NIU with power supply attached fits Wire Gauge > 0.64 mm
into a 70mm deep enclosure.
Conductor Area > 0.34 mm2
85.85mm
(3.38in)
Rated thermal specifications are based
on a clearance of 5.1cm (2in) above
and below the equipment and 2.54cm
3 (1in) to the left of the NIU module.

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 VersaMax Profibus Network Interface Unit
June 2002 GFK-1552D

Termination resistors are needed, as defined in the Profibus

Bus Length Specification DIN 19245 Part 1 section 3.1.2.5.
The maximum bus length using shielded, twisted-pair cable for a
single network segment is 1200 meters. Total network length may
Master Slave Slave Slave Slave Slave
be increased with the use of repeaters, up to a maximum of 3
repeaters per network. Other cable types may be restricted to
shorter bus lengths.
The maximum bus length also depends on the data rate, as shown
in the following table. Termination Required
(Segment 1)

Maximum Bus Length in Meters Kbits per Second

1,200 9.6
1,200 19.2
One terminator must be applied at each end of a network segment.
1,200 93.75
600 187.5
M aster S lave S lave R epeater S lave S lave S lave
400 500
200 1,500
100 3,000; 6,000; 12,000
Term ination R equired Term ination R equired
Often, it is the required bus length that determines the data rate. For (S egm ent 1) (S egm ent 2)
data rates up to 500 kbits/second, follow the stub recommendations
of Profibus Part 1. At 1500 kbits/second the overall drop capacity
should be less than 0.2nF. The maximum length of the stub at 1500 Important: For proper network termination, the terminating devices
kbits/second is 6.6 meters. Cable shielding is recommended at must provide and maintain power. Power is provided by the device on
higher baud rates, to maintain communications integrity in the Pin 6 and Ground is provided on Pin 5. If power is lost to either
industrial environment. terminating device, the network may not operate correctly. Generally,
the network master device is one of the terminating devices. The other
terminating device may be a critical slave device or a separately
Bus Connectors and Termination powered, stand-alone terminator.
The Network Interface Unit provides the Profibus standard female 9-pin
D subminiature connectors. Cable connectors are available from most
VP (6)
fieldbus parts distributors as "Profibus 9-pin D connectors". These
RxD/TxD-P (3) Ru = 390 Ohms
connectors often provide termination resistors and a switch on the
Rt = 220 Ohms
connector to enable/disable termination. Connectors with and without RxD/TxD-N (8)
termination are also available. The connectors generally label the DGND (5) Rd = 390 Ohms
connections for the twisted pair as cable A and cable B. The following
table illustrates the proper assignment of wire to connector to pin to
signal. In addition to the termination shown above, the following compensation
should be added for 12 Mbit bus technology:
Wire Color Connector Pin Signal
5
9
Red B 3 RxD/TxD-P 110nH 4 110nH
To/from 8 To/from
5 DGND another 7
3 another
node 2 node
6 VP 110nH 6 110nH
1
Green A 8 RxD/TxD-N

Bus Grounding
Generally, it is only necessary to ensure that the cable shields are
attached to ground. In most cable connectors, the shield is attached to
the metal housing of the conductor on the cable side and this is brought
to ground by the metal connector on the NIU.
In some installations with large networks or higher data rates, large
ground potentials (greater than 7V) may arise. In these cases, it may
be necessary to ensure all Profibus devices are attached to the same
Protective Earth ground.
Red (B)
RxD/TxD-P (3) RxD/TxD-P (3)
DGND (5) DGND (5)
VP (6) Green (A) VP (6)
RxD/TxD-N (8) RxD/TxD-N (8)